Compacted Iron Guide Chute Design for Melter-Gasifier Permeability
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Solution Overview
Problem
The existing methods for manufacturing molten irons using the blast furnace method face issues such as high energy consumption, equipment wear due to high-temperature briquettes, and difficulties in transporting and melting sponge iron briquettes, which lead to increased costs and operational challenges.
Innovation Solution
An apparatus that includes rollers for compacting reduced materials, a guide chute with a specific guiding surface design, and crushers to manage grain size and flow, along with a melter-gasifier for efficient melting of compacted irons, addressing the challenges of briquette transportation and melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sponge iron briquettes are transported and melted using existing methods, then molten iron production is achieved, but equipment wear increases and energy consumption rises
Solution Approach 1:
The patent changes the physical state parameter of iron ore from sintered agglomerates to fine powder form, and changes the processing method from traditional blast furnace to direct reduction followed by compacting. This parameter change eliminates the need for high-temperature sintering equipment and reduces equipment wear while maintaining production efficiency
Solution Approach 2:
The patent utilizes phase transition by directly reducing iron ore to metallic iron in a reduced state, then compacting it. This avoids the phase transition requirements of traditional sintering and melting processes, reducing energy consumption and equipment thermal stress
2Device complexity
If fine reduced irons are charged into the melter-gasifier, then melting process is simplified, but permeability of gas and liquid in the coal packed bed cannot be ensured
Solution Approach 1:
The patent applies preliminary action by compacting the fine reduced iron into briquettes before charging them into the melter-gasifier. This pre-compaction ensures proper grain size distribution and structural integrity, maintaining gas and liquid permeability in the coal packed bed while simplifying the overall melting process
3Productivity
If raw materials are processed using blast furnace method, then molten iron is produced, but preliminary processing equipment and subsidiary facilities are required
Solution Approach 1:
The patent merges multiple separate processes (ore reduction, iron production, and compacting) into an integrated direct reduction system. This consolidation eliminates the need for separate sintering equipment and subsidiary facilities, reducing device complexity while maintaining high iron production capacity
Solution Approach 2:
The direct reduction apparatus performs multiple functions: it reduces iron ore, produces metallic iron, and can compact the iron into briquettes. This multi-functionality eliminates the need for separate specialized equipment for each process stage, reducing overall device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus enables continuous and efficient production of compacted irons with controlled grain size, reducing equipment wear and energy consumption, and improving the melting process, resulting in cost-effective and stable operation.
Implementation Method 1
a couple of rollers for compacting reduced materials containing fine reduced irons and manufacturing compacted irons
Implementation Method 2
a guide chute for guiding the compacted irons which are discharged from the couple of rollers
Implementation Method 3
crushers for crushing compacted irons which are guided into the guide chute
Implementation Method 4
an apparatus for manufacturing molten irons provided with the apparatus for manufacturing compacted irons
Data Source
AI summary
The present invention relates to an apparatus for manufacturing compacted irons of the reduced materials containing fine reduce irons and an apparatus for manufacturing molten irons provided with the same. The apparatus for manufacturing compacted irons according to the present invention includes a couple of rollers for compacting reduced materials containing fine reduced irons and manufacturing compacted irons, a guide chute for guiding compacted irons which are discharged from the couple of rollers; and crushers for crushing compacted irons which are guided into the guide chute. A guiding surface of the guide chute, which guides the compacted irons, includes a straight slanted surface and a curved slanted surface.